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D A N F O S S F O O D R E T A I L 17/06/2011 / 1
MAKING MODERN LIVING POSSIBLE
Válvulas de Expansión Electrónicas
Danfoss Refrigeration
RefriAmericas Medellin Junio 2011
D A N F O S S F O O D R E T A I L 17/06/2011 / 2
OPCIONES DE AHORRO DE ENERGIA
EN APLICASIONES DE REFRIGERACIÓN
1. Selección adecuado de Intercambiadores de calor.
2. Válvulas de expansión electrónicas.
3. Dimensionamiento de tuberías.
4. Elección adecuada del refrigerante.
5. Opciones de compresores de alta eficiencia.
6. Compresión en paralelo.
7. Sistema de control.
8. Variador de frecuencia en compresores y condensadores.
9. Sistemas en paralelo con variador de frecuencia.
D A N F O S S F O O D R E T A I L 17/06/2011 / 3
CONSUMO TIPICO DE ENERGIA EN UN SUPERMERCADO
COMPRESSORES
30%
VENTILADORES DOS
CONDENSADORES
4%BALCÕES FRIGORÍCOS
16%
INTERNA
21%
EXTERNA
4%
SALAS DE PREPAROS
8%
DIVERSOS
6%
VENTILADORES
4%
AR CONDICIONADO
7%
REFRIGERACIONILUMINACION
OTROS
AIRE CONDICIONADO
D A N F O S S F O O D R E T A I L 17/06/2011 / 4
CONSUMO TIPICO DE ENERGIA EN UN CUARTO FRIO
SH afectan el COP
del compresor
D A N F O S S F O O D R E T A I L 17/06/2011 / 5
Heat
Pre
ssu
re
Enthalpy
A’
B
AE
D
C C’
Condensing temperature
Out temperature
Room temperature
Evaporating temperature
Dtcond.
Dtevap.
PRESION DE EVAPORACION Y CONDENSACION
D A N F O S S F O O D R E T A I L 17/06/2011 / 6
UNIDADES CONDENSADORAS ENFRIADAS POR AIRE
Tcond. = Tamb. + 15°C
D A N F O S S F O O D R E T A I L 17/06/2011 / 7
CUANTO PAGAMOS POR UNCONDENSADOR PEQUEÑO?
T cond = 45°C
Tevap= - 5°C
COP1 = 2,39
T amb = 25°C
T cuarto = 2°C
MT 100 (9 HP)
R22
Q comp. = 7,2 KW
Tcond = 40°C, T evap = - 5°C
Costo $ /mes = 7,2 KW x 18 horas x 30 días/mes x 400 $/KWH = 1.550.000 $ /mes
COP1/COP2 = 12,5%, = $ 190.000 / mes!
$ 2.300.000 al año
T cond = 40°C
Tevap= - 5°CSC=4, SH=5/8
COP2 = 2,73
D A N F O S S F O O D R E T A I L 17/06/2011 / 8
Tevap. = Tcuarto – 6 ó 10 °C
EVAPORADORES ALETADOS
D A N F O S S F O O D R E T A I L 17/06/2011 / 9
CUANTO PAGAMOS POR UNEVAPORADOR PEQUEÑO?
T cond = 40°C
Tevap= - 10°C
COP1 = 2,29
T amb = 25°C
MT 100 (9 HP)
R22
T cuarto = 2°C
Q comp. = 7,2 KW
Tcond = 40°C, T evap = - 5°C
COP1/COP2 = 16% = $ 248.000 / mes!
$ 3.000.000 /año
T cond = 40°C
Tevap= - 5°C
COP2 = 2,73
D A N F O S S F O O D R E T A I L 17/06/2011 / 10
Super Heat:
Diferencia entre la temperatura
de succión y la temperatura de
evaporación o saturación.
SH
CONTROL SOBRECALENTAMIENTO SH
D A N F O S S F O O D R E T A I L 17/06/2011 / 11
SOBRECALENTAMIENTO TOTAL
SH 2 SH 1
SH 1 + SH 2 20°C
SH 1 = 5°C, válvula de Expansión
SH2 Aislamiento.
D A N F O S S F O O D R E T A I L 17/06/2011 / 12
Function of TXV-TE… – SH control
Charges:
Universal MOP
(ballast)
Adsorption
Tcharge -> Pcharge
Pcharge x Adiaphragm = (Pevaporator x Adiaphragm) + Fspring
D A N F O S S F O O D R E T A I L / 13
5 6 8 10 12 1686
88
90
92
94
96
98
100
5 6 8 10 12 16
INDEX
SUPERHEAT ( S2-S1)
RELATIVE COP
“COP vs SH”
D A N F O S S F O O D R E T A I L 17/06/2011 / 14
Injection Control – Superheat
• Large superheat => Low evaporation Temperature => High energy consumption
Air temperature
Refrigerant
temperature
No superheat
Small superheat
Large superheat
Te
mp
era
ture
Position
S3
S4
S2Po
Po
Po
Inlet Outlet
S5
S4
S3
S2
PoS1
D A N F O S S F O O D R E T A I L 17/06/2011 / 15
TEMP. Cuarto Frio = + 2°C
TEMP. Cuarto Frio = + 2°C
T evap. = - 5°C
T evap. = - 10°C
Por cada 1°C que varíe el SH,
la temperatura de succión varia 1°C.
COP1 = 2,73 (óptimo), 7,2 Kw.
COP2 = 2,28 (evap. sin llenar)
SH 1 = 5°CSH 2 = 3°C
SH 1 = 10°CSH 2 = 3°C
COP2/COP1 = 17% más de consumo de energía.
17% = $ 264.000 / mes.
$ 3.150.000 / año
7,2Kw x 400 $/Kw x 18 h/día x 30 días/mes = $ 1.550.000 / mes
D A N F O S S F O O D R E T A I L 17/06/2011 / 16
Tcond = 40°C, T cuarto frio = + 2°C, mismo evaporador, MT 100.
T evap. = - 5°C
T evap. = - 5°C
COP1 = 2,73 (óptimo)Q comp = 7,2 Kw
COP3 = 2,58 (succión mal aislada)
SH 1 = 5°CSH 2 = 3°C
SH 1 = 5°CSH 2 = 15°C
COP3/COP1 = 6%
7,2Kw x 400 $/Kw x 18 h/dia x 30 dias/mes = $ 1.550.000 / mes
6% = $ 93.000 / mes.
$ 1.000.000 / año
CUANTO PAGAMOS POR ALTOS SH?
D A N F O S S F O O D R E T A I L 17/06/2011 / 17
EXPANSION TERMOSTATICA vs ELECTRONICA
D A N F O S S F O O D R E T A I L 17/06/2011 / 18
EXPANSION TERMOSTATICA vs ELECTRONICA
+ Rápida
+ Segura, retornos de líquido
Maneja variaciones de carga altas 90%
Maneja SH estables
Ahorro de energía
Posibilidad de intercambiar orificios
Misma válvula para todos los refrigerantes
Un controlador puede manejar varias válvulas
Precisión en la lectura de los sensores
Menos problema con ubicación de sensores
No ajustes manuales
No hay problemas con variaciones de Pcond.
Opera como solenoide.
Bajo costo inicial
Fácil selección y manejo técnico
Posibilidad de intercambio de orificios
Instalación sencilla
Maneja variaciones de cargas máx. 20%
D A N F O S S F O O D R E T A I L 17/06/2011 / 19
1. VALVULAS ELECTRONICAS MODULANTES
D A N F O S S F O O D R E T A I L 17/06/2011 / 20
AKV Valve
• PWM Principle (Pulse Width Modulating)
AKV closed0 6 12 seconds
AKV Open
Periode time (PT) = 6 seconds
OD % =OT x 100
PTOT = Opening Time.
AK
V O
D %
TimeHomework
Intro
Temp. control
Injection
AKV valve
Defrost
Ctrl. types
Next session
2. DX ELECTRONICA PULSANTE
D A N F O S S F O O D R E T A I L / 21
AKV electronic expansion valves
Pulse width modulated
Integrated solenoid functionExchangeable orificesWide capacity rangeAll refrigerantsHydraulic damping systemCoil program
AKV 10AKV 20
AKV 15
D A N F O S S F O O D R E T A I L / 22
7 CAPACITY STEP
FLARE/SOLDER VERSION
PARTSPROGRAMME
Coil: 2.5 - 5 and 8 meter cable
WIDE TEMP. RANGE
230 - 24 V AC AND DC
18F COIL PRINCIPPLE
ALL REFRIGERANTS
AMMONIA VERSION
SEMIHERMETIC DESIGN
AKV electronic expansion valves
D A N F O S S F O O D R E T A I L / 23
AKV 15
D A N F O S S F O O D R E T A I L / 24
AKV capacity range
5
10
15
20
1 2 3 4 5 6 7
R22 C
apacity in k
W
Orifice no.
1
1,62,54
6,3
10
16
25
50
75
100
1 2 3
25
40
100
AKV 10 AKV 15
200
1 2 3 4 5
100160
250
400
630
AKV 20
400
600
800
63
4
D A N F O S S F O O D R E T A I L 17/06/2011 / 25
CONTROLADORES DX ELECTRONICA
EKC 315AAKC 24P / P2
PARA TODOS LOS REFRIGERANTES
AKV/A AKV/A
D A N F O S S F O O D R E T A I L 17/06/2011 / 26
CONTROLADORES DX ELECTRONICA
PARA TODOS LOS REFRIGERANTES
AKV/A AKV/A
D A N F O S S F O O D R E T A I L 17/06/2011 / 27
AHORRO DE ENERGIA CON DX ELECTRONICA
7,2Kw x 400 $/Kw x 18 h/día x 30 días/mes = $ 1.550.000 / mes
23,2% = $ 360.000 / mes
15% = 230.000 / mes
$ 2.760.000 / año
D A N F O S S F O O D R E T A I L 17/06/2011 / 28
How do measure superheat?
Evaporator
Surface temperature: S5
Refrigerant
temperature S1
Pressure Po
Air on temperature
S3
Air of temperature
S4
Refrigerant
temperature S2
One measurement to much on refrigerant side...
D A N F O S S F O O D R E T A I L 17/06/2011 / 29
• Po [°C] is equal to S1
S5
S4
S3
S2
PoS1
S2S1
Po
S2S1
PoPo [°C] is not equal to S1,
superheat = S2-Po[°C]
How do measure superheat?
D A N F O S S F O O D R E T A I L 17/06/2011 / 30
Injection Control – Superheat
5K
S2
Temp.
°C
S1 S2
AKS32R
AKS32R (Te)
Comparison of two ways of measuring the superheat signal:SH = S2 - S1 or SH = S2 – Te (true value)(Te must be calculated from a Pe measurement)
D A N F O S S F O O D R E T A I L 17/06/2011 / 31
Injection Control – Superheat
5K
7K
S2
AKS32R (Te)
Temp.
°C
S1 S2
AKS32R
Comparison of two ways of measuring the superheat signal:SH = S2 - S1 (bad measure)SH = S2 – Te (true value)(Te must be calculated from a Pe measurement)
D A N F O S S F O O D R E T A I L 17/06/2011 / 32
Pressure Transmitter advantage
• Po is a better measurement than S1 and is used/required in newest controller versions
S5
S4
S3
S2
PoS1
D A N F O S S F O O D R E T A I L 17/06/2011 / 33
Porque DX electrónica ahorra energía?
Adaptive superheat control
D A N F O S S F O O D R E T A I L / 34
S2-To
Length
MSS start
Stable Unstable Stable
S2
To
Injection function
D A N F O S S F O O D R E T A I L 17/06/2011 / 35
3 2 1
Minimum stable superheat =>
Best evaporator performance
1
2
3
Minimum stable superheat - Theory
When an evaporator is “under filled” with refrigerant, the superheat signal is high and very stable at the outlet of the evaporator. Only a small area of the evaporator is utilised => degraded performance.
When the evaporator is almost full, liquid drops of refrigerant will be present at the outlet of the evaporator and this will result in an unstable superheat signal. This will result in control hunting problems => degraded performance.
If the evaporator is “over filled” with refrigerant, liquid will flow back into the suction line => Degraded system performance + risk of damaging the compressor. The superheat signal will be very stable at 0K.
D A N F O S S F O O D R E T A I L 17/06/2011 / 36
86
88
90
92
94
96
98
100
5 6 8 10 12 16
MSS curve Relative COP
Superheat
Minimum stable superheat - Theory
The superheat is reduced until the signal becomes unstable.
Then superheat is increased a bit until stability is found
followed by a new reduction and so on!
It happen in all conditions.
D A N F O S S F O O D R E T A I L 17/06/2011 / 37
Injection Control – Electronic valve
Superheat
Q0
Lo
ad
ran
ge f
or
the e
vap
ora
tor
MSS = f (Q0,T0 etc.)
Unstable zone
Stable zone
Adaptive valve
Homework
Intro
Temp. control
Injection
AKV valve
Defrost
Ctrl. types
Next session
D A N F O S S F O O D R E T A I L 17/06/2011 / 38
The adaptive superheat for the Danfoss
controller enables extra savings
compared to other suppliers.
Adaptive vs. Fixed superheat control
• Other suppliers are often using a fixed set point for the control of the evaporator superheat.
• In theory this means that the evaporator can be fully utilised in one operation point, but this would require a very time consuming manual adjustment of the set point which is never carried out in praxis.
• A fixed superheat control algorithm will not detect when liquid is present at the evaporator outlet. Hence the superheat set point must be set in a “safe” distance from the minimum stable superheat in order to ensure that liquid will not flow back into the suction line.
Other suppliers
D A N F O S S F O O D R E T A I L 17/06/2011 / 39
Adaptive vs. Fixed superheat control
• The measuring accuracy of the evaporating pressure and the gas outlet temp. must be very accurate in order to control superheat at low values.
• Competitors often use low cost and thereby low precision pressure transmitters.
• The result is that the superheat set point has to be set a quite high value in order to eliminate the risk of having liquid flow back to the suction line due to lousy measuring accuracy.
• The result is of course even higher savings with the Danfoss adaptive control of superheat.
D A N F O S S F O O D R E T A I L 17/06/2011 / 40
Saving example:
MT100 (9 HP hermetic):7,2Kw x 400 $/Kw x 18 h/dia x 30 dias/mes =
$ 1.550.000 / mes
9% = $ 140.000 / mes.
$ 1.680.000 / año
Medium sized supermarket with 3
compressor MT100:
Save energy: $ 420.000 / mes
Total $ 5.040.000 / year
Adaptive vs. Fixed superheat control
• The adaptive superheat control will typically obtain a 2-3 K lower superheat reference than with a competitor fixed superheat reference.
• By lowering the superheat, the suction pressure can be increased by approx. the same amount. The energy savings by increasing suction pressure by 1K is typically 3 %.
• So the energy savings by using Danfoss adaptive superheat control will typically be 6-9 % compared to a fixed superheat control.
D A N F O S S F O O D R E T A I L 17/06/2011 / 41
Aplicaciones:
• Instalaciones con variaciones de cargas térmicas
• Instalaciones con variación de presión de condensación
• Túneles de congelación
• Intercambiadores de placas
• Intercambiadores con variación de carga (caudal, diferencial temp.)
• Equipos que requieran protección y precisión
D A N F O S S F O O D R E T A I L 17/06/2011 / 42
How to select the right size AKV
D A N F O S S F O O D R E T A I L 17/06/2011 / 43
How to select the right size AKV
1. Find evaporator capacity
2. Calculate pressure drop across AKV
3. Correct for sub-cooling
4. Correct capacity to pull-down capability
5. Select correct AKV size
6. Determine correct liquid line dimension
D A N F O S S F O O D R E T A I L 17/06/2011 / 44
How to select the right size AKV
1. Find evaporator capacity
D A N F O S S F O O D R E T A I L 17/06/2011 / 45
How to select the right size AKV
2. Calculate pressure drop across AKV
D A N F O S S F O O D R E T A I L 17/06/2011 / 46
How to select the right size AKV
3. Correct for sub-cooling
D A N F O S S F O O D R E T A I L 17/06/2011 / 47
How to select the right size AKV
4. Correct capacity to pull-down capability
D A N F O S S F O O D R E T A I L 17/06/2011 / 48
How to select the right size AKV
5. Select correct AKV size
D A N F O S S F O O D R E T A I L 17/06/2011 / 49
How to select the right size AKV
6. Determine correct liquid line dimension
D A N F O S S F O O D R E T A I L 17/06/2011 / 50
Questions